Clayton 1602G, Owner'S Manual, Page: 13 / 24

13
TROUBLE SHOOTING AND PROBLEM SOLVING
Problem Solution
1. Smoke puffs from furnace
• Check chimney draft. Check for blocked chimney or flue pipe. Use mirror to check
chimney clearance.
• Check ash pit — if it is too full, empty.
• Make sure furnace room is not too airtight.
• Make sure all of chimney mortar connections are airtight.
• Check ash drawer. Make sure it’s airtight.
• Check chimney for possible down-draft caused by taller surrounding trees or objects.
Correct with proper chimney vent cap.
• Check the possibility of a cold chimney forcing cool gases backward. Remedied by
properly insulating chimney with non-combustible liner — non-combustible insulation.
• Fuel may be too green.
• Make sure no other fuel burning devices are connected to the chimney impairing the
draft.
• Check chimney draft, it should be .06 inches of water column. This service is provided by
a certified chimney sweep.
2. Inadequate heat being delivered to your
home
• Check home insulation — is it adequate?
• Check hook-up to furnace — is it installed correctly?
• Cool air inlet may be inadequate or furnace room too airtight.
• Make sure your hot air duct (and other duct work) is airtight.
• If furnace room is warm but your home isn’t, check back draft dampers.
• Is air to the blower available?
3. Excess smoke or flames coming out door
when refueling
• Wait 15 seconds and open door SLOWLY — then refuel.
• Check length of flue pipe to chimney. Your unit should be within six (6) feet of your
chimney.
• Make sure chimney cap is not too close to the top of the chimney.
• Check chimney draft — make sure chimney flue pipe is clean and chimney is of adequate
height.
• Make sure you’re not suffocating the fire with excessive amounts of unburned coal.
• Slide baffle should be pulled out prior to load door opening.
4. Distribution blower vibrating
• Tighten blower wheel to motor shaft.
• Check for bad fan bearings.
5. Distribution blower continues to run or
will not run
• Check fan limit or heat sensor and cable.
• Check to see that blower is properly wired. (See Wiring and Assembly Instructions).
• Check fuse box or power source.
• Check power supply.
6. Draft blower continues to run or will not
run
• Check wiring.
• Check thermostat or thermostat wire for short.
• Make sure temperature is calling for heat.
7. Odor from first fire • The odor from new steel should disappear in a few hours.
• If the odor remains, call you dealer immediately. A bad weld can cause a fume leak.
8. Excessive Creosote
• Make sure your unit is serviced by its own proper chimney.
• Check length of flue pipe and its connections.
• Make sure you are burning the smallest, hottest fire to adequately heat your home.
• Also see Solutions to Problem one.
9. If the fire goes out or does not hold over
night
• Poor Draft.
• Incorrect damper settings.
• Improper firing methods if burning coal.
• More combustion air needed.
• Coal not sized to the furnace. We recommend 1” to 3” diameter pieces of coal.
• Ashes, if allowed to accumulate in the ash pit, will not allow passage of the required air
for combustion. Keep ash pit clean.
• This furnace is not to be used with an automatic stoker unless so certified.